3-Dimensional Universal Tube Connector System

ABSTRACT

The present invention includes a system for connecting tubes or rods, which are preferably uni-directional pultruded, filament wound, or roll-wrapped carbon-fiber tubes or rods, together to form trusses and other structures using a series of connector pieces preferably bonded together with adhesive.

REFERENCE TO RELATED APPLICATIONS

This application claims one or more inventions which were disclosed inProvisional Application Ser. No. 61/323,046, filed Apr. 12, 2010,entitled “3-DIMENSIONAL UNIVERSAL TUBE CONNECTOR SYSTEM”. The benefitunder 35 USC §119(e) of the United States provisional application ishereby claimed, and the aforementioned application is herebyincorporated herein by reference.

This application is also a continuation-in-part application ofapplication Ser. No. 12/698,220, filed Feb. 2, 2010, entitled“3-DIMENSIONAL UNIVERSAL TUBE CONNECTOR SYSTEM”, which claimed thebenefit of Provisional Application Ser. No. 61/149,439, filed Feb. 3,2009, entitled “3-DIMENSIONAL UNIVERSAL TUBE CONNECTOR SYSTEM”.Theaforementioned applications are hereby incorporated herein by reference.

BACKGROUND OF THE INVENTION

1. Field of the Invention

This invention relates to fabricated tubular truss and frame structures,and in particular to structures assembled using carbon-fiber tubes orrods.

2. Description of Related Art

Trusses and frame type structures have been used for many years as anefficient method to create lightweight, yet extremely stiff supportstructures. Trusses are particularly useful when a load must be carriedover long distances, such as in building roofs, bridges, and cranes.

Prior art exists for various types of truss connector systems. U.S. Pat.No. 435,156 (Schmemann) discloses a design for an arch pipe truss foruse in roofs. Schmemann uses rod members with threaded ends, which arethreaded in joint connectors with mating receptacles. This design,however, does not allow the user to select the angle for the diagonalarbitrarily.

U.S. Pat. No. 2,487,169 (Newell) discloses a joint connector used forcreating pipe trusses. This connector is fabricated by intersectingplates fitted axially into the pipe end. This joint must be weldedtogether, especially for each individual joint.

U.S. Pat. No. 3,985,459 (Gilb) discloses a ridge joint connectorassembly. In this joint, two pairs of sheet metal fastener plates areplaced on the inside and outside faces of the ends of lumber members.This joint does not allow for the connection of tubes and rods, nor doesit permit the connection of members orthogonal to the first two members.U.S. Pat. No. 4,050,210 (Gilb) also discloses a ridge connector forlight composite trusses composed of lumber top chords and metal webs.Here, pairs of U-shaped connectors are used, along with pins and slotsto hold the members together.

U.S. Pat. No. 4,161,088 (Gugliotta) discloses a pipe-and-ball trussarray for supporting deck surfaces. This joint includes a sphericallyshaped joint center, with tubular members bolted to various locations onthe sphere. U.S. Pat. No. 4,915,533 (De la Haye) discloses a couplingpiece for joining two or more rods. This patent uses a round orpolygonal shaped piece, into which the rods are bolted at specificlocations. U.S. Patent No. 5,310,273 (Hara) discloses a joint structurefor removably attaching a ball member to an end of a bar to form a trussstructure, which engages using a tension rod.

U.S. Pat. No. 4,650,361 (Seuster) discloses a joint for truss structuresincluding fiber composite material. In particular, the joint attachesreflector panels in a truss support structure for a radio telescope, andthe truss bars and reflector panels are made from carbon-fibercomposites. Here, the joint includes a ball into which bolts arefastened, with the ends attached to the fiber composite bars.

U.S. Pat. No. 3,229,998 (Pennington), U.S. Pat. No. 4,667,505 (Sharp),U.S. Pat. No. 4,870,856 (Sharp), U.S. Pat. No. 4,840,201(Botsolas), U.S.Pat. No. 5,007,666 (Kyfes), and U.S. Design Patent No. D362,916(Cetrulo) disclose various types of split or clam-shell shaped joiners.These methods, however, do not incorporate means to connect diagonalconnectors, and hence cannot be used exclusively to form a trussstructure. Similarly, U.S. Pat. No. 6,032,430 (Soukup), U.S. Pat. No.5,346,237 (Wang), U.S. Pat. No. 6,604,710 (Ohmer), and U.S. Pat. No.5,711,131 (Thomas) all disclose connection methods for bars; however, ineach case the directions of the individual members is predetermined bythe specific connector. That is, the user needs multiple types ofconnectors to fabricate an entire structure with multiple internalangles.

U.S. Pat. No. 7,171,792 (Windahl et al.) discloses a pipe and cabletruss system. Here, two inclined members are joined at an angle, formingthe peak of the truss. Vertical members and tension cables are used tohold the structure together. In order to connect the tension cables,tabs with holes are attached to the rigid pipe members. These tabs,however, would not be adequate for high compression or out-of-planeloads. In addition, the use of tabs prohibits the attachment of tubesand rods in place of the tension cables.

Several companies offer joints for connecting tubes. Hy-Gain Corporation(Lincoln, Nebraska) manufactures antenna support structures. Hy-GainModel LJ-105CA contains a clamshell type joint that is used to connectmultiple tubes inline and at 90 degree angles. Using these connectors,however, one is unable to attach tubes along the third axis. Inaddition, there is no means to connect compressional diagonal membersthrough this type of joint. Cushcraft Corporation (Manchester, NewHampshire) also supplies clamshell type attachment joints for antennasupport structures (Big Thunder Series); however, like with the Hy-Gainmodels, a single universal joint cannot be utilized to create an entiretruss or frame.

AirDynamics Corporation (New York, N.Y.) provides fittings to connectcarbon fiber tubes. These fittings are tube splices used by sliding oneend into each tube. Adhesive is applied to the fitting prior toinsertion within the tube, and the glue line lies between the outerperiphery of the fitting and the inner tube wall.

SUMMARY OF THE INVENTION

A system connects uni-directional pultruded, filament wound, orroll-wrapped tubes or rods together to form trusses and other structuresusing a series of connector pieces bonded together. The tubes or rodsare preferably carbon fiber tubes or rods. The connector pieces arepreferably bonded together with adhesive. In one embodiment, theadhesive is an epoxy adhesive.

A universal joint connector allows simple, easy, and inexpensivefabrication of complex structures from pultruded, filament wound, orroll-wrapped carbon-fiber tubes or rods. This method is applicable toall types of materials for both the tubes and rods, as well as theconnectors; however, the preferred embodiment uses pultruded, filamentwound, or roll-wrapped carbon fiber tubes and/or rods and injectionmolded carbon-fiber reinforced plastic connectors. The universalconnectors are preferably fabricated from three parts: an outer piece,an inner piece, and preferably one to four diagonal tube connectors.

In one embodiment, a connector system includes tubes or rods anduniversal connectors. Each universal connector includes a firstconnector bracket and a second connector bracket, where the firstconnector bracket and the second connector bracket attach together toform a structure having at least one opening into which the tubes orrods can be placed. The universal connector also includes at least onediagonal member having an opening into which a tube or rod can beplaced. The diagonal member is aligned at an angle in relation to atleast one of the openings in the structure. The universal connector alsoincludes adhesive ridge gauges on an inner surface of the opening of thediagonal member and in the opening of the structure.

In another embodiment, a universal connector includes a first connectorbracket and a second connector bracket, where the first connectorbracket and the second connector bracket attach together to form astructure having at least one opening into which the tubes or rods canbe placed. The universal connector also includes at least one diagonalmember having an opening into which a tube or rod can be placed. Thediagonal member is aligned at an angle in relation to at least one ofthe openings in the structure. The universal connector also includesadhesive ridge gauges on an inner surface of the opening of the diagonalmember and in the opening of the structure.

In yet another embodiment, a truss structure includes universalconnectors. The universal connectors each include a first connectorbracket and a second connector bracket, where the first connectorbracket and the second connector bracket attach together to form astructure having at least one opening into which the tubes or rods canbe placed. The universal connector also includes at least one diagonalmember having an opening into which a tube or rod can be placed. Thediagonal member is aligned at an angle in relation to at least one ofthe openings in the structure. The truss structure also includes tubesor rods, which are connected by the universal connectors to formlongitudinal members, a plurality of cross-members orthogonal to thelongitudinal members, and a plurality of diagonal elements connectingthe longitudinal members on a diagonal.

A method constructs a truss structure from tubes or rods and universalconnectors. Each universal connector includes a first connector bracketand a second connector bracket, where the first connector bracket andthe second connector bracket attach together to form a structure havingat least one opening into which the tubes or rods can be placed. Theuniversal connector also includes at least one diagonal member having anopening into which a tube or rod can be placed. The diagonal member isaligned at an angle in relation to at least one of the openings in thestructure. The method includes the step of forming longitudinal membersby connecting the tubes or rods linearly with universal connectors. Themethod also includes the steps of connecting the longitudinal memberswith a plurality of cross-members using universal connectors such thatthe cross-members are orthogonal to the longitudinal members and bracingthe truss structure by connecting a plurality of diagonal elements ontwo different longitudinal members and two different cross-members usinguniversal connectors.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 shows an assembled 90 degree angle universal connector with 4diagonal members attached in an embodiment of the present invention.

FIG. 2 a shows an outer connector bracket of the universal connector ofFIG. 1.

FIG. 2 b shows an inner connector bracket of the universal connector ofFIG. 1.

FIG. 3 shows a close-up of the outer connector bracket of FIG. 2 a,including adhesive ridge gauges.

FIG. 4 shows diagonal members of FIG. 1 in various orientations.

FIG. 5 shows a diagonal member attached to an outer connector bracket atan arbitrary angle.

FIG. 6 a shows a front side view of an assembled 90 degree angleuniversal connector with four diagonal members attached and tubes bondedinto place.

FIG. 6 b shows a back side view of the assembled 90 degree angleuniversal connector shown in FIG. 6 a.

FIG. 7 shows the universal connector of FIGS. 6 a and 6 b with the innerconnector bracket hidden.

FIG. 8 shows a rectangular truss made from tubes and universal tubeconnectors.

FIG. 9 shows a close-up of one end of the truss structure of FIG. 8.

FIG. 10 a shows a top down view of a 60 degree angle connector of thepresent invention.

FIG. 10 b shows a cross-sectional side view of a 60 degree angleconnector of the present invention.

FIG. 11 shows the outer connector bracket of the 60 degree angleconnector of FIG. 10.

FIG. 12 a shows a portion of the outer connector bracket of FIG. 11.

FIG. 12 b shows a cross-sectional view along lines 12 b-12 b of FIG. 12a, through the midplane of the outer connector bracket of FIG. 11,showing the tube stop feature.

FIG. 13 shows a tube end connector of the present invention.

FIG. 14 shows a triangular truss including the 60 degree angleconnectors of FIG. 10 and the tube end connectors of FIG. 13.

FIG. 15 shows the structure of FIG. 14 with a triangular plate bonded tothe tube end connectors of FIG. 13.

FIG. 16 shows a close-up view of the end of the structure shown in FIG.15, showing the plate and tube end connectors.

FIG. 17 a shows a tube side connector of the present invention.

FIG. 17 b shows another view of the tube side connector of FIG. 17 a.

FIG. 18 shows a truss structure with tube side connectors bonded intoplace.

FIG. 19 a shows the truss structure of FIG. 18 with a rectangular platebonded to the tube side connectors.

FIG. 19 b shows another view of the truss structure of FIG. 19 a.

FIG. 20 a shows a 3-way 90 degree connector of the present invention.

FIG. 20 b shows the outer portion of the 3-way connector of FIG. 20 a.

FIG. 20 c shows the inner portion of the 3-way connector of FIG. 20 a.

FIG. 21 shows a 3-way 90 degree connector with diagonal members andtubes or rods bonded in place.

FIG. 22 a shows a 2-dimensional T connector of the present invention.

FIG. 22 b shows an exploded view of the two brackets that make up the Tconnector of FIG. 22 a.

FIG. 23 shows a 2-dimensional T connector of FIG. 22 with diagonalmembers bonded in place.

FIG. 24 a shows a 2-dimensional 90 degree connector of the presentinvention.

FIG. 24 b shows an exploded view of the two brackets that form theconnector of FIG. 24 a.

FIG. 25 shows a 2-dimensional 90 degree connector of FIG. 24 with adiagonal member bonded in place.

FIG. 26 a shows a 2-dimensional 135 degree connector of the presentinvention.

FIG. 26 b shows an exploded view of the two brackets that form theconnector of FIG. 26 a.

FIG. 27 shows a 2-dimensional 135 degree connector of FIG. 26 with adiagonal member bonded in place.

FIG. 28 a shows an inline connector of the present invention.

FIG. 28 b shows an exploded view of the two brackets that form theconnector of FIG. 28 a.

FIG. 29 a shows a 2-dimensional 4-way connector of the presentinvention.

FIG. 29 b shows an exploded view of the two brackets that form theconnector of FIG. 29 a.

FIG. 30 shows a 2-dimensional 4-way connector of FIG. 29 a with diagonalmembers bonded in place.

FIG. 31 shows a structure with several different types of connectors andcarbon-fiber tubes or rods.

FIG. 32 a shows a back side view of another 90 degree universalconnector of the present invention.

FIG. 32 b shows a front side view of the 90 degree universal connectorof FIG. 32 a.

FIG. 33 a shows a back side of the universal connector of FIG. 32 a withdiagonal members bonded in place.

FIG. 33 b shows a front side of the universal connector of FIG. 32 awith diagonal members bonded in place.

FIG. 34 a shows a back side view of another 60 degree universalconnector of the present invention.

FIG. 34 b shows a front side view of the 60 degree universal connectorof FIG. 34 a.

FIG. 35 a shows a back side of the universal connector of FIG. 34 a withdiagonal members bonded in place.

FIG. 35 b shows a front side of the universal connector of FIG. 34 awith diagonal members bonded in place.

FIG. 36 shows the diagonal member of FIG. 1 with a smaller receptacle.

FIG. 37 a shows an angle termination connector in an embodiment of thepresent invention.

FIG. 37 b shows the angle termination connector of FIG. 37 a with adiagonal member attached.

FIG. 38 a shows an inline connector in an embodiment of the presentinvention.

FIG. 38 b shows the inline connector of FIG. 38 a with a diagonal memberattached.

FIG. 39 shows an alternate embodiment for the inline connector of FIG.38 a.

FIG. 40 a shows an alternate embodiment for the inline connector of FIG.39.

FIG. 40 b shows the inline connector of FIG. 40 a with four diagonalmembers attached.

FIG. 41 a shows a tube end insert piece in an embodiment of the presentinvention.

FIG. 41 b shows the tube end insert of FIG. 41 a placed inside the endof a tube.

FIG. 42 shows eight universal connector pieces combined to form a3-dimensional 90 degree universal connector in an embodiment of thepresent invention.

FIG. 43 a shows an outer view of a 3-dimensional 90 degree universalconnector piece in an embodiment of the present invention.

FIG. 43 b shows an inner view of the 3-dimensional 90 degree universalconnector piece of FIG. 43 a.

FIG. 44 shows the 3-dimensional 90 degree universal connector of FIG. 42with tubes inserted into the receptacles for each primary orthogonalaxis and three diagonal members attached.

FIG. 45 shows a 3-dimensional 90 degree universal connector utilizingfour components and attached to a plate.

FIG. 46 a shows a universal connector including four individualconnector pieces and a 2-dimensional 4-way connector.

FIG. 46 b shows an alternate view of the connector of FIG. 46 a.

FIG. 47 shows two 3-dimensional 90 degree universal connectors and one90 degree angle universal connector bonded together.

DETAILED DESCRIPTION OF THE INVENTION

The present invention includes a system for connecting tubes or rodstogether to form trusses and other structures using a series ofconnector pieces bonded together. Either tubes or rods, or anycombination of both tubes and rods, may be used in the connector systemof the present invention. The connector system of the present inventionis preferably designed for uni-directional pultruded, filament wound(fiber wound), or roll-wrapped tubes or rods. In a preferred embodiment,the tubes or rods are made of carbon fiber. Carbon-fiber products, suchas carbon-fiber tubes or rods, can be used for a wide range ofapplications. There is great interest in purchasing these raw buildingmaterials and using them to fabricate custom structures.

In a preferred embodiment, the connectors and the tubes or rods form atruss structure. The connector pieces are preferably bonded togetherwith adhesive. In one embodiment, the adhesive is an epoxy adhesive.

A universal joint connector allows simple, easy, and inexpensivefabrication of complex structures from tubes or rods. This method isapplicable to all types of materials for both the tubes and rods, aswell as the connectors; however, the preferred embodiment usespultruded, filament wound, or roll-wrapped carbon fiber tubes/rods andinjection molded carbon-fiber reinforced plastic connectors.

The present invention includes a universal joint for constructingtrusses, where the diagonals can be set at any angle, and the diagonalmembers can be either in tension or compression. In preferredembodiments, the diagonal members are tubes. A single joint can be usedto construct an entire truss or frame structure out of tubes or rods,regardless of the size and diagonal angles. In other words, one onlyneeds to design the shape of the truss and not any individualconnectors.

Unlike prior art brackets, which can only connect elements in one plane,the present invention includes a method and system for connecting a tubeor rod out of plane (that is, perpendicular to the two in-planedirections). Also unlike the prior art, the connectors of the presentinvention can connect the tubes or rods at any angle, giving a highdegree of versatility to a single connector design. When constructing atruss structure, both of these connection methods preferably need to beutilized. The third dimension gives the truss both depth and width, andthe diagonal members are necessary for rigidity due to shear andtorsional loads.

While screws or other fasteners are used in the present invention, theyare preferably used to simply hold the part together during bonding. Allof the strength preferably comes from an adhesive bond.

The universal connector is preferably fabricated from three parts: anouter piece (outer connector bracket), an inner piece (inner connectorbracket), and one or more diagonal tube connectors (diagonal members).In preferred embodiments, there are one to six diagonal members.

An embodiment of the present invention is shown in FIG. 1, which depictsan assembled 90 degree angle universal connector 100. The universalconnector 100 includes an inner connector bracket 1 and an outerconnector bracket 2 that form a clamshell. Since diagonal elements arean integral part of most truss structures, this capability is preferablyadded to the design through an additional diagonal member 3. Thediagonal member 3 is shown in FIG. 1 secured in place by adhesive;however, there are other ways of securing the diagonal member 3including, but not limited to, fasteners, clips and weldments. In orderto facilitate ease of assembly and proper pressure during adhesivecuring, a fastener 4 is preferably used.

The outer connector bracket 2 and the inner connector bracket 1 areshown separated in FIGS. 2 a and 2 b, respectively. The holes 20 locatedon the flat surfaces are used to align the parts correctly duringassembly and bonding. In preferred embodiments, fasteners 4, shown inFIG. 1, for example rivets, screws, or bolts with nuts, are placedthrough the holes to align the parts and draw them together for properbonding. If screws are used, then one connector piece would include athrough hole, and the other piece would include a tapped hole. Thefastener is inserted during bonding, and can optionally be removed oncethe adhesive is fully cured.

Adhesive ridge gauges, or ribs, 21, preferably located on the interiorsurfaces of the connector brackets 1 and 2, help to properly align thetubes or rods, as well as provide proper spacing between the wallsurfaces to ensure adequate adhesive thickness. FIG. 3 shows a close-upof the outer connector bracket 2 and the adhesive ridge gauges 21.

Diagonal members 3 are shown in various orientations in FIG. 4. Eachdiagonal member 3 includes a tab 7 and a receptacle 8. Like with theinner connector bracket 1 and the outer connector bracket 2, adhesiveridge gauges 41, or ribs, are preferably included on the inner surfacesof the diagonal members for proper tube or rod alignment and to ensureadequate adhesive thickness.

An important feature of this design is the ability to align the diagonalmembers 3 at any angle 51, since this angle is not pre-determined Inother words, the determination of the diagonal angle can be made by thefabricator when bonding the diagonal member 3 to the inner connectorbracket 1 and the outer connector bracket 2. Eliminating designrestrictions on this angle in turn removes geometric restrictions on theassembled structure. For example, if the connector angle 51 wasrestricted to 45 degrees, the user would be required to design thecomplete truss or frame structure to include only this angle, whichwould severely limit the use of the system. The ability to allow angle51 to vary between 0 and 90 degrees allows the designer great latitudein truss construction.

The universal connector 100 is shown in FIGS. 6 a and 6 b withcarbon-fiber tubes 60 inserted and bonded into place. Although tubes areshown, carbon fiber rods or other tubes or rods could alternatively beused. The user bonds a tube or rod into the diagonal member 3 by eithersliding it in or placing it first into the outer connector bracket 2,and then fixing the inner connector bracket 1 into place. Adhesive ispreferably added to all mating surfaces, and the tubes or rods are thenplaced in the requisite channels. In one embodiment, the adhesive is anepoxy adhesive. The combination of the two-piece configuration, theinternal adhesive-control ridges/ribs, diagonal members, and the holesfor fasteners, make up the primary gusset assembly system. The connectorsystem is shown in FIG. 7 with the inner connector bracket 1 hidden.

An assembled rectangular truss structure 400 is shown in FIG. 8. Thetruss is made up of universal connectors 100 and tubes or rods 60. Thetubes or rods are preferably made of carbon fiber. A close-up of one endof the truss structure 400 is shown in FIG. 9. The corner brackets 91 atthe terminal end of the truss structure 400 are preferably made bycutting one leg off of the inner connector bracket 1 and the outerconnector bracket 2.

The inner connector bracket 1 and the outer connector bracket 2 can bemanufactured in different shapes to facilitate creation of other trussgeometries, and are not restricted to purely 90 degree connectors. Oneexample of non-right angle connector geometries is shown in FIGS. 10 aand 10 b, which show a 60 degree angle connector 500. The 60 degreeangle connector 500 is made up of an inner connector bracket 15 and anouter connector bracket 16. The two pieces form a clamshell structure,and allow for diagonal members 3 to be added in the same manner as shownin FIG. 1.

FIGS. 11 and 12 a show the inside surfaces of the outer connectorbracket 16 of the 60 degree angle connector 500. Internal ribs 21 areincluded, similar to those in the universal connector 100, for propertube or rod positioning and adhesive thickness control. In addition,tube stops 71 are preferably included in the connector 500 to make surethe two tubes that make the 60 degree angle are set at the proper depth.FIG. 12 b shows a section view along lines 12 b-12 b of FIG. 12 a,showing the tube stops 71 and internal ribs 21.

To facilitate the attachment of truss structures to foundations, as wellas add mounting plates to the ends of the truss, a tube end connector131, as shown in FIG. 13, can be utilized. The tube end connector 131has a flange portion 132, holes for mounting fasteners 133, and atubular portion 134 to accept a tube or rod, which is preferably acarbon-fiber pultruded or filament wound tube or rod.

FIG. 14 shows a triangular truss 600 with 60 degree angle universalconnectors 500, tubes or rods 60, and tube end connectors 131. FIG. 15shows a plate 151 optionally bonded to the tube end connectors 131 ofthe truss structure 600. FIG. 16 shows an alternate view of the end ofthe truss structure 600 of FIG. 15.

In addition to the tube end connectors, other mounting pieces can beoptionally added to the truss structures. One example is a tube sideconnector 171 shown in FIGS. 17 a and 17 b. This connector includes asemi-circular channel 172, one or more internal ribs 21, and a flat side173. The tube side connector 171 is preferably included in a truss orframe structure by bonding a tube or rod, which is preferably acarbon-fiber tube or rod, into the semi-circular channel 172 and usingthe flat side 173 for bonding to a support structure or for affixing amounting plate to the truss. One example of the tube side connectorincluded in a truss structure 700 is shown in FIG. 18. FIGS. 19 a and 19b show the truss structure 700 with a flat plate 191 optionally bondedto the tube side connectors.

The universal connector can be cut at various positions in order to formsimpler connectors. For example, the flange in the third dimension canbe removed to form a 2-dimensional T-shaped connector. Similarly, both2-dimensional and 3-dimensional corner pieces, as well as 2-dimensionalstraight splice connectors, can be formed using the same method. In thisway, the universal connector assembly can be utilized for virtually anytype of structural joint including, but not limited to, 2-dimensional,3-dimensional, corner, T-shape, and diagonal angles.

Individual connectors for each type of joint can also be manufacturedfor end-users who do not wish to cut down the universal connector. Asampling of some of these simplified connectors is shown in FIGS. 20through 31. FIGS. 20 a through 20 c show a 3-dimensional corner bracketconnector 201. The inner connector bracket 202 and the outer connectorbracket 203 are utilized using the aforementioned methods for theuniversal connector 100. The 3-dimensional corner bracket connector 201is shown in FIG. 21 with three diagonal members 3 bonded into place atarbitrary angles. Also, six tubes 60 are shown bonded into theconnectors 201.

FIGS. 22 a and 22 b show a 2-dimensional T connector 221. Due tosymmetry, both the top 222 and bottom 222 halves of the clamshell whichmake up the T connector 221 are identical. The complete 2-dimensional Tconnector 221 is shown in FIG. 23 with two diagonal members 3 attached.

FIGS. 24 a and 24 b show a 2-dimensional 90 degree connector 241. Thetop half 242 of the connector and the bottom half 243 of the connectorform the 90 degree connector 241. The complete 2-dimensional 90 degreeconnector 241 is shown in FIG. 25 attached to a diagonal member 3.

FIGS. 26 a and 26 b show a 2-dimensional 135 degree connector 261. Thetop half 262 of the connector and bottom half 263 of the connector formthe 135 degree connector 261. The complete 2-dimensional 135 degreeconnector 261 is shown in FIG. 27 with a diagonal member 3 attached.

FIGS. 28 a and 28 b show an inline connector 281. Due to symmetry, boththe top 282 and bottom 282 halves of the clamshell which comprise theinline connector 281 are identical.

FIGS. 29 a and 29 b show a 2-dimensional 4-way connector 291 of thepresent invention. Due to symmetry, both the top 292 and bottom 292halves of the clamshell which make up the 4-way connector 291 areidentical. The complete 4-way connector 291 is shown in FIG. 30 withfour diagonal members 3 attached.

FIG. 31 shows an example of how each simplified connector can beutilized to form a structure 800. This structure includes 3-dimensionalcorner bracket connectors 201, 2-dimensional T connectors 221,2-dimensional 90 degree connectors 241, 2-dimensional 135 degreeconnectors 261, inline connectors 281, and 2-dimensional 4-wayconnectors 291. As exemplified in this figure, there are a very largenumber of possibilities for the shape of the resulting structure.

An alternative embodiment for the 90 degree angle universal connector100 is shown in FIG. 32. FIG. 32 a shows a back side view of a 90 degreeangle universal connector 350 and FIG. 32 b shows a front side view ofthe 90 degree angle universal connector 350.

This connector differs from the connector 100 shown in FIG. 1 byreplacing the center tube receptacles with alignment holes for diagonalmembers 3, as shown in FIGS. 33 a and 33 b. The inner connector bracket1 shown in FIG. 1 is replaced by an inner connector bracket 351, and theouter connector bracket 2 is replaced by an outer connector bracket 352.

An alternative embodiment for the 60 degree angle universal connector500 is shown in FIG. 34. FIG. 34 a shows a back side view of a 60 degreeangle universal connector 550 and FIG. 34 b shows a front side view ofthe 60 degree angle universal connector 550. This connector differs fromthe connector 500 shown in FIG. 10 by replacing the center tubereceptacles with alignment holes for diagonal members 3, as shown inFIGS. 35 a and 35 b. The inner connector bracket 15 shown in FIG. 10 isreplaced by an inner connector bracket 555, and the outer connectorbracket 16 is replaced by an outer connector bracket 556.

FIG. 36 shows an alternative embodiment for a diagonal member 360 wherethe tab portion 361 is the same as shown in FIGS. 1 and 4, but thereceptacle portion 362 has a reduced diameter to accommodate a smallertube. Other potential variations include, but are not limited to, alarger receptacle, a smaller tab, or a larger tab. These additionalembodiments of the diagonal member give greater versatility to astructural design including tubes and the connectors in embodiments ofthe present invention. Some examples for receptacle diameters include,but are not limited to, ¼″, ⅜″, ½″ ¾″, and 1″ (to accept tubes withthose diameters). Some examples of tab widths include, but are notlimited to, approximately ¾″, 1″, 1.5″ and 2″. The larger widths anddiameters would be preferably used to accommodate larger diameter tubes.A preferred embodiment for a diagonal member includes a ½″ receptacle(which fits a ½″ diameter tube) and an approximately 1″ width for thetabs. Other receptacle diameters and tab widths for the diagonal membersmay alternatively be used, and any combination of receptacle diameterand tab width may be chosen for particular designs to accommodate theneeds of that particular design.

The diagonal members 3 and 360 and the variations of the diagonalmembers discussed herein are preferably attached to the connectors shownin the figures by adhesive; however, there are other ways of securingthe diagonal member 3 and 360 including, but not limited to, fasteners,clips and weldments. The diagonal member 360 shown in FIG. 36, as wellas the variations for the diagonal member discussed in this paragraph,may be used in any combination with any of the connectors discussedherein.

FIGS. 37 a and 37 b show an angle termination connector 370 in anembodiment of the present invention. The flat side 371 bonds to anotherflat surface, such as a plate, while the diagonal member 3, shown inFIG. 37 b, connects to the angled side 372 and is used to connect to theend of a tube of the structure. Note that, in this figure and those thatfollow, the diagonal member 3 is attached to the connector by adhesive.While this attachment method is preferred, other attachment means,including, but not limited to, fasteners, clips and weldments, couldalternatively be used.

FIGS. 38 a and 38 b show an inline connector 380 in an embodiment of thepresent invention. This connector can be used as a splice to join twoinline tubes, or as a means to add another tube at an arbitrary anglerelative to the primary tube. This is accomplished using a diagonalmembers 3, as shown in FIG. 38 b. An alternate embodiment of the inlineconnector 390, which has a double flange 381 instead of the singleflange 381 shown in FIG. 38 a, is shown in FIG. 39. Connector 390 canaccept diagonal members on either side of the inline portion 382.Another embodiment of the inline connector 405, which has analternatively shaped double flange 406 able to accept multiple diagonalmembers 3, is shown in FIGS. 40 a and 40 b.

A tube end insert 410 is shown in FIG. 41 a. This component is used toattach additional parts to the truss structure off the end of a tube.FIG. 41 b shows the tube end insert 410 bonded into place within the endof a tube 60. The hole 411 in the end of the tube insert 410 can besmooth or threaded, and allows for additional connections.

One example of a 3-dimensional 90 degree universal connector 420 forcreating truss and frame structures is shown in FIG. 42. This connectorincludes up to eight pieces 421 bonded together. Individual components421 are shown in FIGS. 43 a and 43 b. In FIG. 44, connector 420 is shownwith tubes 60 bonded into place in the three primary orthogonaldirections. In addition to tubes 60 being inserted into the receptacles,diagonal members 3 can be attached to one or more of the flat sides of auniversal connector 420. FIG. 44 shows the universal connector 420 withthree diagonal members attached; however, up to twelve diagonal memberscan be attached simultaneously in the embodiment shown, giving greatversatility to the design.

In addition to the complete connector, individual components of theuniversal connector 420 can be excluded, giving further versatility. Forexample, FIG. 45 shows a universal connector 450 comprised of fourindividual connector pieces 421, and providing a flat surface convenientfor bonding to a flat plate 451. The connectors 421 are preferablybonded to the flat plate 451 with an adhesive.

FIGS. 46 a and 46 b show a universal connector 450 and a 2-dimensional4-way connector piece 292 bonded together to form a new connector 460.

FIG. 47 shows two 3-dimensional 90 degree universal connector pieces 421and one 90 degree angle universal connector outer bracket 2 in anembodiment of the present invention. The design of these connectorsallows them to be bonded together as shown in FIG. 47.

In addition to the manufacturing method presented here, instead offabricating and assembling the inner connector bracket 1 and outerconnector bracket 2 as two separate pieces, an alternative embodimentutilizes a single injection molded part, with the two halves combinedinto one. In this embodiment, the tubes or rods would slide into theconnector in a similar fashion to standard plastic tube fittings,instead of the connector assembled in two halves.

Accordingly, it is to be understood that the embodiments of theinvention herein described are merely illustrative of the application ofthe principles of the invention. Reference herein to details of theillustrated embodiments is not intended to limit the scope of theclaims, which themselves recite those features regarded as essential tothe invention.

1. A connector system, comprising: a) a plurality of tubes or rods; andb) a plurality of universal connectors, each universal connectorcomprising: i) a first connector bracket; ii) a second connectorbracket, such that the first connector bracket and the second connectorbracket attach together to form a structure having at least one openinginto which a plurality of the tubes or rods can be placed; iii) at leastone diagonal member having an opening into which a tube or rod can beplaced, wherein the diagonal member is aligned at an angle in relationto at least one of the openings in the structure; and iv) a plurality ofadhesive ridge gauges on an inner surface of the opening of the diagonalmember and in the opening of the structure.
 2. The connector system ofclaim 1, wherein an approximate diameter of the opening of the diagonalmember is selected from the group consisting of ¼″, ⅜″, ½″, ¾″ and 1″.3. The connector system of claim 1, wherein the diagonal member furthercomprises a tab for connecting the diagonal member to the firstconnector bracket or the second connector bracket.
 4. The connectorsystem of claim 3, wherein an approximate width of the tab is selectedfrom the group consisting of ¾″, 1″, 1.5″ and 2″.
 5. The connectorsystem of claim 3, wherein an approximate width of the tab is 1″ and anapproximate diameter of the opening of the diagonal member is ½″.
 6. Theconnector system of claim 1, further comprising at least one angletermination connector comprising: a first L-shaped connector brackethaving a first side and a second side at a 90-degree angle to the firstside; and a second L-shaped connector bracket having a first side and asecond side at a 90-degree angle to the first side; wherein the firstside of the first L-shaped connector bracket and the first side of thesecond L-shaped connector bracket form a surface for the diagonal memberto attach to, and the second side of the first L-shaped connectorbracket and the second side of the second L-shaped connector bracketform a single flat surface.
 7. The connector system of claim 1, whereinat least one of the universal connectors comprises an inline connectorcomprising a first connector bracket and a second connector bracketconnected together to form a single opening into which a tube or rod maybe placed.
 8. The connector system of claim 7, wherein the firstconnector bracket and the second connector bracket of the inlineconnector comprise at least one flange for connecting to at least onediagonal member.
 9. The connector system of claim 1, further comprisingat least one tube end insert for insertion into an end of at least onetube or at least one rod.
 10. The connector system of claim 1, whereinthe tubes or rods are made of carbon fiber.
 11. The connector system ofclaim 1, wherein the connector system couples at least two tubes or rods12. A universal connector, comprising: a) a plurality of connectorbrackets, wherein each connector bracket comprises: i) a first side; ii)a second side orthogonal to the first side; iii) a third side orthogonalto both the first side and the second side; iv) a first curved channelaligned along a first axis where the first side and the second sidemeet; v) a second curved channel aligned along a second axis where thefirst side and the third side meet; and vi) a third curved channelaligned along a third axis where the second side and the third sidemeet; wherein the plurality of connector brackets attach together toform a structure having at least one opening formed by the channels intowhich a plurality of tubes or rods can be placed; and b) at least onediagonal member having an opening into which a tube or rod can beplaced, wherein the diagonal member is aligned at an angle in relationto at least one of the openings in the structure.
 13. The connector ofclaim 12, further comprising a plurality of adhesive ridge gauges on aninner surface of the opening of the diagonal member and in the channelsof the connector brackets.
 14. The connector of claim 12, wherein theconnector brackets comprise at least three connector brackets.
 15. Theconnector of claim 12, wherein the connector brackets comprise eightconnector brackets aligned such that up to six tubes or rods can beplaced in the connector brackets.
 16. The connector of claim 12, whereinchannels from four connector brackets form each opening.
 17. Theconnector of claim 12, wherein at least three connector brackets areadhesively bonded together.
 18. The connector of claim 12, wherein atleast one tube or rod is adhesively bonded to at least one of the curvedchannels.